Systems and methods for manual handling

ABSTRACT

Method and systems for manual handling are described. In one embodiment, a holding section, a distribution section and a manual section are provided. The holding section is adapted to hold the container during manual handling. The distribution section is adjacent the holding section and includes a robot adapted to select and pick containers from the holding section. The robot is disposed to distribute the container. The manual section is disposed adjacent the conveyor. The manual section is adapted for inspection or filling of the container. Additional methods and systems are disclosed.

CROSS-REFERENCE TO A RELATED APPLICATION

This application is a divisional application of Ser. No. 13/412,370filed on Mar. 5, 2012 which application claims priority under 35 U.S.C.§119(e) to U.S. Provisional Patent Application No. 61/449,523 filed onMar. 4, 2011. The entire disclosure of U.S. Ser. No. 13/412,370 andProvisional Patent Application No. 61/449,523 are hereby incorporatedherein by reference.

FIELD

The present application relates generally to the technical field ofautomated filling centers. In a specific example, the presentapplication may relate to a high volume fulfillment center, e.g., a highvolume pharmacy and to systems and devices used in filling prescriptionsand prescription orders at a high volume pharmacy.

BACKGROUND

A high-volume pharmacy, such as a mail order pharmacy, may process andfill a large number of prescriptions and prescription orders. Automatedsystems may be used by a high volume pharmacy to process and fulfillprescriptions.

Frequently, more than one prescription drug is required to complete aprescription order. The fulfillment of prescriptions in the prescriptionorder may be fulfilled in different areas of the high-volume pharmacy.After fulfillment, the fulfilled prescriptions are gathered into acomplete prescription order for shipping.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an example system according to an exampleembodiment;

FIG. 2 is a block diagram of an example order processing device that maybe deployed within the system of FIG. 1, according to an exampleembodiment;

FIG. 3 is a schematic representation of the manual fulfillment device orthe review device that may be deployed within the system of FIG. 1,according to an example embodiment;

FIG. 4 is a schematic representation of the manual fulfillment device orthe review device that may be deployed within the system of FIG. 1,according to an example embodiment;

FIG. 5 is a block diagram of a control unit that may be deployed withinthe device of FIGS. 3 and 4, according to an example embodiment;

FIG. 6 is a block diagram of a holding subsystem that may be deployedwithin the control unit of FIG. 5, according to an example embodiment;

FIG. 7 is a block diagram of an distribution subsystem that may bedeployed within the control unit of FIG. 5, according to an exampleembodiment;

FIG. 8 is an example process flow illustrating a method of manualhandling, according to an example embodiment;

FIG. 9 is an example process flow illustrating a method of manualhandling, according to an example embodiment; and

FIG. 10 is a block diagram of a machine in the example form of acomputer system within which a set of instructions for causing themachine to perform any one or more of the methodologies discussed hereinmay be executed or stored.

DETAILED DESCRIPTION

Example systems and methods for manual handling are described. In thefollowing description, for purposes of explanation, numerous specificdetails are set forth in order to provide a thorough understanding ofexample embodiments. It will be evident, however, to one of ordinaryskill in the art that these embodiments may be practiced without thesespecific details.

Generally, a prescription order is generated for a high volume pharmacy.The prescription order may include more than one prescription drug forfulfillment. Each prescription drug in a prescription order is an ordercomponent of the prescription order. Generally, the order components arecontainers having a quantity of a prescription drug therein.

The prescription drugs may be dispensed at various sections of the highvolume pharmacy. Some prescription orders may require manual fulfillmentof order components. Other order components that are fulfilled byautomation may require manual inspection. The selection and distributionof order components necessitating manual fulfillment or inspection isprovided by a holding section, a distribution section and a manualsection. In general, manual handling includes manual fulfillment ofprescription drugs or inspection of a container and/or prescriptiondrugs. The holding section holds the order components not needing manualhandling while the order component requiring manual handling isdistributed at the distribution section. In some embodiments, thedistribution section may distribute the order component not requiringmanual handling to the holding section. Manual handling occurs at themanual section, from which the order component is returned for reunitingwith companion order components to group the prescription order.

FIG. 1 is a block diagram of an example system 100, according to anexample embodiment. While the system 100 is generally described as beingdeployed in a high volume pharmacy, the automated filling system 100 mayotherwise be deployed. The system 100 may include an order processingdevice 102 in communication with a network manager device 106 over anetwork 104.

The order processing device 102 may receive information aboutprescriptions being filled at a pharmacy in which the order processingdevice 102 is deployed. The order processing device 102 may track aprescription order as it is fulfilled. The order processing device 102may make routing decisions and/or order consolidation decisions for aprescription order. The order processing device 102 may operate on itsown or in combination with the network manager device 106.

Examples of the network 104 include Mobile Communications (GSM) network,a code division multiple access (CDMA) network, 3rd GenerationPartnership Project (3GPP), an Internet Protocol (IP) network, aWireless Application Protocol (WAP) network, a WiFi network, or an IEEE802.11 standards network, as well as various combinations thereof. Otherconventional and/or later developed wired and wireless networks may alsobe used.

The network manager device 106 is a device operated by an entity atleast partially responsible for creation and/or management of thepharmacy benefit. While the network manager operating the networkmanager device 106 is typically a pharmacy benefit manager, otherentities may operate the network manager device 106 either on behalf ofthemselves, the PBM, or another entity. The network manager device 106may include a processor, memory to store data and instructions, and acommunication device.

Some of the operations of the PBM that operates the network managerdevice 106 may include the following. A member (or a person on behalf ofthe member) attempts to obtain a prescription drug at a retail pharmacylocation where the member can obtain drugs in a physical store from apharmacist or pharmacist technician, or in some instances through mailorder drug delivery from a mail order pharmacy location. The member mayalso obtain a prescription drug directly or indirectly through the useof a machine, such as a kiosk, vending unit, mobile electronic device,or a different type of computing device.

The member may have a co-pay for the prescription drug that reflects anamount of money that the member is responsible to pay the pharmacy forthe prescription drug. The money paid by the member to the pharmacy maycome from the personal funds of the member, a health savings account(HSA) of the member or the member's family, a health reimbursementarrangement (HRA) of the member or the member's family, a flexiblespending accounts (FSA) of the member or the member's family, or thelike. An employer of the member may directly or indirectly fund orreimburse the member or an account of the member for the co-pay.

The amount of the co-pay paid by the member may vary by the benefit planof the client with the PBM. The member's co-pay may be based on a flatco-pay (e.g., $10), co-insurance (e.g., 10%), and/or a deductible (e.g.,for first $500 of annual prescription drug spend) for certainprescription drugs, certain types of prescription drugs, and/or allprescription drugs.

In certain instances, the member may not pay the co-pay or may only payfor a portion of a co-pay for a prescription drug. For example, if theusual and customary cost for a generic version of a prescription drug is$4, and the member's flat co-pay is $20 for the prescription drug, themember may only pay $4 to receive the prescription drug. In anotherexample involving a worker's compensation claim, no co-pay may be due bythe member for the prescription drug.

In conjunction with receiving the co-pay (if any) from the member anddispensing the prescription drug to the member, the pharmacy submits aclaim to the PBM for the prescription drug. The PBM may perform certainadjudication functions including verifying the eligibility of themember, reviewing the formulary to determine appropriate co-pay,coinsurance, and deductible for the prescription drug, and performing adrug utilization review (DUR) on the member. The PBM then adjudicatesthe claim associated with the prescription drug and provides a responseto the pharmacy following performance of the aforementioned functions.As part of the adjudication, the client (or the PBM on behalf of theclient) ultimately reimburses the pharmacy for filling the prescriptiondrug when the prescription drug was successfully adjudicated. Theaforementioned adjudication functions generally occur before the co-payis received and the prescription drug dispensed. However, the operationsmay occur simultaneously, substantially simultaneously, or in adifferent order. In addition, more or less adjudication functions may beperformed as part of the adjudication process. Adjudication may beperformed through the use of a machine, such as a computer system.

The amount of reimbursement paid to the pharmacy by the client and/ormember may be based at least in part on the type of pharmacy network inwhich the pharmacy is included. Other factors may be used to determinethe reimbursement amount in addition to the type of pharmacy network.The above methodologies may be implemented by executing instructions inthe network manager device 106.

The system 100 may include a loading device 108, a sorting device 110,an automated dispensing device 112, a manual fulfillment device 114, areview device 116, a cap device 118, an accumulation device 120 and/or apacking device 122.

The loading device 108 may load prescription containers by a roboticarm, pick and place mechanism, or the like. In one embodiment, theloading device 108 has robotic arms or pickers to grasp a container andmove it to and from a pallet. The pallet may be located on a conveyorassembly.

The sorting device 110 may receive containers and may identify thecontainers that belong to a particular prescription drug order. Thesorting device 110 may group the containers according to theprescription drug order in which they belong.

The automated dispensing device 112 includes one or more devices thatdispense prescription drugs or pharmaceuticals into containers inaccordance with one or more prescription orders. Various automateddispensing systems are available commercially such as e.g., the systemsold under the trademark OPTIFILL by AmerisourceBergen Corporation.

The manual fulfillment device 114 provides for manually fulfillingprescriptions. In general, a manual fulfillment may include operationsat least partially performed by a pharmacist or pharmacy technician. Forexample, a person may retrieve a supply of the prescribed drug, may makean observation, may count out a prescribed quantity of drugs and placethem into a container, or the like. Some portions of the manualfulfillment process may be automated by use of a machine. For example,counting of capsules, tablets or pills may be at least partiallyautomated (e.g., through use of a pill counter). In some embodiments,the automated fulfillment is integrated with the manual fulfillmentoperations. Certain automated fulfillment may be performed before manualfulfillment and vice versa. The automated fulfillment for a prescriptionmay be paused to allow for the manual fulfillment to be completed. Oncethe devices receive an input that manual fulfillment is complete, thenthe automated fulfillment is released and fulfillment proceedsautomatically.

The review device 116 may process containers to be reviewed by apharmacist. Fulfilled prescriptions may be reviewed and/or verified by apharmacist, as may be required by state or local law. In otherembodiments, prescriptions are reviewed and/or verified for qualityassurance. A pharmacist or other licensed person who may dispensecertain drugs in compliance with local and/or other laws may operate thereview device 116 and visually inspect a container that has been filledwith a prescription drug. The pharmacist may review, verify, and/orevaluate drug quantity, drug strength, and/or drug interaction concerns,or otherwise perform pharmacist services.

The cap device 118 may be used to cap a container. In some embodiments,the cap device 118 may provide a type of cap in accordance with apatient preference (e.g., a preference regarding child resistance). Thecap device 118 may provide a crown portion, such as a ring or top, tocap the container. The ring or top operates cooperatively to providechild resistance. In other embodiments, no ring or top over a containermay provide an easily-opened cap (e.g., for patients with fine motordisabilities).

The accumulation device 120 accumulates various prescription drugs in aprescription order. The accumulation device 120 may accumulateprescription containers from various area of the high volume fulfillmentcenter. For example, the accumulation device 120 may accumulateprescription containers from the automated dispensing device 112, themanual fulfillment device 114 and the review device 116.

The packing device 122 packages a prescription order in preparation forshipping the order. The packaging device 122 may box or bag thefulfilled prescription order for delivery. The packaging device 122 mayfurther place inserts into the box or bag. The packaging device 122 maylabel the box or bag with the address. The packaging device 122 may sortthe box or bag for mailing in an efficient manner (e.g., sort bydelivery address).

While the system 100 in FIG. 1 is shown to include single devices 102,106, 108, 110, 112, 114, 116, 118, 120, 122 multiple devices may beused. The devices 102, 106, 108 110, 112, 114, 116, 118, 120, 122 may bethe same type of device or may be different device types. When multipledevices are present, the multiple devices may be of the same device typeor may be a different device type. Moreover, system 100 shows a singlenetwork 104; however, multiple networks can be used. The multiplenetworks may communicate in series with each other to link the devices102, 106, 108 110, 112, 114, 116, 118, 120, 122 or in parallel to linkthe devices 102, 106, 108, 110, 112, 114, 116, 118, 120, 122. Multipledevices may share processing and/or memory resources. The devices102-122 may be located in the same area or in different locations. Forexample, the devices 102-122 may be located in a building or set ofadjoining buildings. The devices 102-122 may be interconnected (e.g. byconveyors), networked or otherwise in contact with one another.

In some embodiments, at least some of the functionality of the orderprocessing device 102 may be included in the network manager device 106.In other embodiments, at least some of the functionality of the orderprocessing device 102 may be included in the manual fulfillment device114 and/or the review device 116 and vice versa.

The order processing device 102 may be in a client-server relationshipwith the network manager device 106, a peer-to-peer relationship withthe network manager device 106, or in a different type of relationshipwith the network manager device 106.

The order processing device 102 and/or the network manager device 106may be in communication directly (e.g., through local storage) and/orthrough the network 104 (e.g., in a cloud configuration or software as aservice) with a database 124 (e.g., as may be retained in memory orotherwise). The database 124 may store order data 126, member data 128and/or client data 130.

The order data 126 may include data used for completion of theprescription, such as prescription materials. Prescription materials area type of order materials that include an electronic copy of informationregarding the prescription drug for inclusion with the fulfilledprescription. The prescription materials may include electronicinformation regarding drug interaction warnings, recommended usage,possible side effects, expiration date, date of prescribing, etc.

The member data 128 includes information regarding the membersassociated with the benefit manager. Examples of the member data 128include name, address, telephone number, e-mail address, prescriptiondrug history, and the like. The member data 128 may include a clientidentifier that identifies the client associated with the member and/ora member identifier that identifies the member to the client. The memberdata 128 may include a member identifier that identifies the clientassociated with the patient and/or a patient identifier that identifiesthe patient to the client. The member data 128 may also include, by wayof example, dispensation preferences such as type of label, type of cap,message preferences, language preferences, or the like. The member data128 may be accessed by the devices 102, 106-122 to obtain the necessaryinformation for fulfilling the prescription and shipping theprescription drugs.

The client data 130 includes information regarding the clients of thebenefit manager. Examples of the client data 130 include company name,company address, contact name, contact telephone number, contact e-mailaddress, and the like.

FIG. 2 illustrates the order processing device 102, according to anexample embodiment. The order processing device 102 may be used by oneor more operators to generate prescription orders, make routingdecisions, and/or make prescription order consolidation decisions. Forexample, the prescription order may be comprised of order components.The order processing device 102 may receive instructions to fulfill anorder without operator intervention. An order component may include aprescription drug fulfilled in a container by the system 100. The orderprocessing device 102 may direct an order component to the manualfulfillment device 114 or the review device 116 and direct othercomponents to the automated dispensing device 112. The order processingdevice 102 may direct all order components to the accumulation device120 for aggregation before shipping. The order processing device 102 maydirect the order components directly to the packing device 122 if theprescription order does not require accumulation from various areas ofthe pharmacy for completion. The order processing device 102 may bedeployed in the system 100, or may otherwise be used.

The order processing device 102 may include an order verificationsubsystem 202, an order control subsystem 204 and/or an order trackingsubsystem 206.

The order verification subsystem 202 may communicate with the networkmanager device 106 to verify the eligibility of the member, review theformulary to determine appropriate co-pay, coinsurance, and deductiblefor the prescription drug, and/or perform a drug utilization review(DUR).

The order control subsystem 204 controls various movements of thecontainers and/or pallets along with various filling functions duringprogression through the system 100. For example, the order controlsubsystem 204 may identify the prescribed drug as needing to befulfilled manually and may direct the container or order component tothe manual fulfillment device 114 to achieve the manual fulfillment. Thedevices 108-122 may be interconnected by a system of conveyors or othercontainer movement systems. Thus, the order control subsystem 204 maycontrol various conveyors to deliver the pallet from the loading device108 to the manual fulfillment device 114, for example.

The order tracking subsystem 206 tracks a prescription order as itprogresses (or stops) toward fulfillment. The order tracking subsystem206 may track, record and/or update order history, order status or thelike. The order tracking subsystem 206 may store data locally (e.g., ina memory) or at the order data 124.

FIG. 3 illustrates a manual fill center 300 according to an exampleembodiment. The manual fulfillment device 114 and/or the review device116 may include the manual fill center 300.

The manual fill center 300 may include a holding section 302, adistribution section 304, multiple manual sections 306, and a controlunit 308. The pallets 312 securely hold one or more containers 314therein. The container 314 may represent an order component of aprescription order. More than one order component may constitute aprescription order.

The holding section 302 is disposed between the distribution section 304and a feed conveyor 316. The feed conveyor 316 supplies pallets 312 withthe containers 314 for manual handling.

A first transfer area 318 is provided as a connection between theholding section 302 and the feed conveyor 316. The pallet 312 may beidentifiable by having a label, bar code, RFID tag, or the like thereon.The first transfer area 318 may include a reader 320 (e.g., RFID reader,optical reader or the like) for reading a label (e.g., RFID tag, barcode, QR code, etc.) on the pallet 312 and a transfer actuator 322 fortransferring the pallet 312 from the feed conveyor 316 to the holdingsection 302. The transfer actuator 322 may be a lift transfer unit(e.g., from Bosch Rexroth of Hoffman Estates, Ill.), or may be a roboticmechanism to lift or push the pallet 312 from the feed conveyor 316 tothe holding section 302. The transfer actuator 322 may be one or moredevices, mechanisms, and/or methods adapted to move a pallet 312 to orfrom one conveyor to another (e.g., by sliding, lifting and replacing,and/or otherwise moving, transferring, transporting, and/or relocating).The reader 320 may be a barcode reader, an RFID reader, an image scanner(e.g., an image scanner equipped with and/or directly or indirectlyconnected to a computer system equipped with an optical characterrecognition system), and/or other optical, mechanical, electrical,and/or audio device capable of reading and/or otherwise obtaininginformation from the object being read, e.g., a label.

The holding section 302 may include a first holding conveyor 324, asecond holding conveyor 326, a first holding transfer actuator 328 and asecond holding transfer actuator 330. The first holding conveyor 324 maybe disposed substantially parallel to the second holding conveyor 326adjacent the feed conveyor 316. The second holding conveyor 326 may bedisposed adjacent the distribution section 304. The first and secondholding conveyors 324, 326 may move in opposite directions so as to movethe pallets 312 in opposite directions. The first holding transferactuator 328 and the second holding transfer actuator 330 may bedisposed at ends of the first and second holding conveyors 324, 326.

For example, as a pallet 312 reaches the end of the first holdingconveyor 324, it is moved to the second holding conveyor 326 by thefirst holding transfer actuator 328. At the opposite end, the secondholding transfer actuator 330 may move a pallet 312 from the secondholding conveyor 326 to the first holding conveyor 324. In anembodiment, the directions of the conveyors 324, 326 and the transferactuators 328, 330 may be reversed. Other conveyors may be used, such asa continuous, circulating conveyor (e.g., a substantially oval-shapedconveyor).

The distribution section 304 may include a robot 332, a scanner 334 anda labeler 336. In an example embodiment, the container 314 is unloadedby the robot 332 and distributed to the manual section 306. The robot332 may be adapted to pick the container 314 from the pallet 312 on thesecond holding conveyor 326 and scan or label the container 314. Thecontainer 314 may be empty and/or uncapped. In some embodiments, thecontainer 314 may not be empty, may contain a quantity of a prescriptiondrug and/or may be capped. In an embodiment in which the container 314is empty and uncapped, the robot 332 may be adapted to obtain thecontainer 314 and move it to the labeler 336 for labeling. The robot 332may be adapted to move the labeled container 314 to the scanner 334 forscanning The scanner 334 may include an image sensor that captures animage of the container 314 with the label and/or a barcode scanner. Therobot 332 may be adapted to spin the container 314 for the scanner 334to obtain attributes, such as identifying data, from the label. Otherdevices may be used to remove the container 314 from the pallet 312, orthe container 314 may be manually removed.

After the robot 332 has picked the desired container 314 from the pallet312, the second holding conveyor 326 may begin to move the pallet 312away from the distribution section 304 to allow other pallets 312 tomove adjacent the distribution section 304. The first holding conveyor324, the second holding conveyor 326, the first holding transferactuator 328 and the second holding transfer actuator 330 may circulatethe pallet 312 in a holding pattern. In some embodiments, the robot 332will not empty the pallet 312. That is, the pallet 312 will containorder components that make up a prescription order together with thecontainer 314 picked by the robot 332. In this case, order componentsnot selected by the robot 332 may be already filled or may be filled ata later time outside of the manual fill center 300. The order componentsin the pallet 312 may await the return of the containers 314 from themanual section 306. Upon return, the robot 332 may be adapted to placethe container 314 into the pallet 312 with its respective ordercomponents that together complete a prescription order.

The distribution section 304 may further include a delivery conveyor 338and a return conveyor 340. The manual section 306 may include a handlingarea 342. The delivery conveyor 338 receives the container 314 from therobot 332 at a first end 344 and delivers the container 314 to thehandling area 342 at a second end 346. The return conveyor 340 receivesthe container 314 at the second end 346 and delivers the container 314to the distribution section 304 at the first end 344. The handling area342 may be operated by a pharmacy technician, pharmacist or the like tofill the container 314 with a prescription drug and/or to inspect thecontainer 314. Inspection may include, for example, verifying correctdata on the label, verifying quantity of the prescription drug, and/orverifying the correct prescription drug. In some embodiments, containers314 may be introduced into the manual fill center 300 by manual labelingof the container 314 and/or manual fulfillment of the prescription drugin the container 314 at the handling area 342 with placement on thereturn conveyor 340 to merge with a prescription order on the pallet312.

The delivery conveyor 338 and the return conveyor 340 may be straight orcurved according to the space available and location of the handlingarea 342.

Referring now to FIG. 4, a manual fill center 400 is illustratedaccording to an example embodiment. The manual fill center 400 may bedeployed in the manual fulfillment device 114 and/or the review device116. The manual fill center 400 may include a holding section 402, adistribution section 404, multiple manual sections 406 and a controlunit 408. The holding section 402 is disposed adjacent the distributionsection 404.

The holding section 402 may include a stationary pallet 412 for holdingcontainers 314. The distribution section 404 may include a robot 414, ascanner 416 and a labeler 418. The robot 414 is adapted to pickcontainers and place them in the pallet 412. The robot 414 may pick thecontainer 314 and move it to the scanner 416 and/or the labeler 418 toscan or label the container 314. In an example embodiment, containers314 are unloaded by the robot 414 and containers 314 are distributed tothe manual section 406. The container 314 may be empty and/or uncapped.In other embodiments, the container 314 may not be empty, may contain aquantity of a prescription drug and/or may be capped or uncapped. In oneembodiment in which the container 314 is empty and uncapped, the robot414 may be adapted to obtain the container 314 and move it to thelabeler 418 for labeling. The robot 414 may be adapted to move thelabeled container 314 to the scanner 416 for scanning. The scanner 416may include an image sensor that captures an image of the container 314with the label and/or a barcode scanner. The robot 414 may be adapted tospin the container 314 for the scanner 416 to obtain attributes from thelabel. In an embodiment in which the container 314 contains a quantityof a prescription drug, the container 314 may be labeled before reachingthe manual fill center 400. In such an embodiment, the robot 414positions the container 314 to be scanned by the scanner 416 withoutlabeling.

The distribution section 404 may further include a delivery conveyor 420and a return conveyor 422. The manual section 406 may include a handlingarea 424. The delivery conveyor 420 and the return conveyor 422 may bestraight or curved according to the space available and location of themanual section 406. The delivery conveyor 420 may deliver the container314 to the robot 414 and may deliver the container 314 to the handlingarea 424. The return conveyor 422 receives the container 314 at thehandling area 424 and delivers the container 314 to the distributionsection 304. The return conveyor 422 may move the container 314 from therobot 414 to exit the manual fill center 400. The handling area 424 maybe operated by a pharmacy technician, a pharmacist, or the like toeither fill the container 314 with a prescription drug and/or to inspectthe container 314. Inspection may include, for example, verifyingcorrect data on the label, verifying quantity of the prescription drug,and/or verifying the correct prescription drug. In some embodiments,containers 314 may be introduced into the manual fill center 400 bymanual labeling of the container 314 and/or manual fulfillment of theprescription drug in the container 314 at the handling area 424 withplacement on the return conveyor 422 to merge with a prescription orderat the stationary pallet 412. The containers 314 not requiring manualinspection or manual fulfillment but are apart of a prescription orderwith a container requiring manual inspection or manual fulfillment maybe moved to the stationary pallet 412 for temporary storage.Prescription orders not requiring any containers 314 to be manuallyinspected or manually fulfilled may be unloaded directly from thestationary pallet 412 to the return conveyor 422.

Referring to FIG. 5, the control unit 308 is illustrated according to anexample embodiment. The control unit 308 may be deployed in the manualfill center 300, 400. The control unit 308 may be communicativelyconnected to one or more components in the holding section 302, 402, thedistribution section 304,404 and/or the manual section 306, 406. Thecontrol unit 308 may include a holding subsystem 502 and a distributionsubsystem 504. The holding subsystem 502 enables the manual fill center300 to manage operations of the holding section 302, 402. Thedistribution subsystem 504 enables the manual fill center 300, 400 tomanage operations of the distribution section 304, 404.

FIG. 6 illustrates an example holding subsystem 502 that may be deployedin the control unit 308, order processing device 102 or otherwisedeployed in another system. One or more modules are communicativelycoupled and included in the holding subsystem 502 to enable managementof the pallet 312 and/or the container 314 in the holding section 302,402. The modules of the holding subsystem 502 that may be included are aposition module 602 and/or an identification module 604. Other modulesmay also be included.

In some embodiments, the modules of the holding subsystem 502 may bedistributed so that some of the modules are deployed in the manualfulfillment device 114 and/or the review device 116 and some modules aredeployed in the order processing device 102. In one embodiment, themodules are deployed in memory and executed by a processor coupled tothe memory. The functionality contained within the modules 602, 604 maybe combined into a lesser number of modules, further divided among agreater number of modules, or redistributed among existing modules.Other configurations including the functionality of the modules 602, 604may be used.

The position module 602 manages movement of the pallet 312 with thecontainer 314 while at the holding section 302. For example, theposition module 602 may command movement of the first and second holdingconveyors 324, 326 and the first and second holding transfer actuators328, 330. The position module 602 may determine the position that thecontainer 314 is placed and held in the stationary pallet 412 while atthe holding section 402.

The identification module 604 may be in communication with the reader320 that may read an RFID tag attached to the pallet 312. Theidentification module 604 may communicate with the processing device 102and/or the loading device 108 to access information on the prescriptionorders in the pallet 312 to determine whether any order components ofthe prescription orders require manual handling. The identificationmodule 604 may access information on the position of the ordercomponents within the pallet 312 from the position module 602 and selectdesired order components via the robot 332, 414. The identificationmodule 604 may communicate with the scanner 334, 416 to determine theproper distribution of the order component.

FIG. 7 illustrates an example distribution subsystem 504 that may bedeployed in the control unit 308, order processing device 102, orotherwise deployed in another system. One or more modules arecommunicatively coupled and included in the distribution subsystem 504to distribute the container 314 in the distribution section 304, 404.The modules of the distribution subsystem 504 that may be included are ascan module 702, a label module 704, a robot module 706 and/or aconveyor module 708. Other modules may also be included.

In some embodiments, the modules of the distribution subsystem 504 maybe distributed so that some of the modules are deployed in the manualfulfillment device 114 and/or the review device 116 and some modules aredeployed in the order processing device 102. In one embodiment, themodules are deployed in memory and executed by a processor coupled tothe memory. The functionality contained within the modules 702-708 maybe combined into a lesser number of modules, further divided among agreater number of modules, or redistributed among existing modules.Other configurations including the functionality of the modules 702-708may be used.

The scan module 702 may be in communication with the scanner 334, 416and/or order processing device 102, for example. The scan module 702 mayobtain data regarding the attributes of the container 314 and/or itslabel. Data obtained by the scan module 702 may be stored locally orremotely, such as at the database 124. Data obtained by the scan module702 may be cross referenced to data that is already stored locally orremotely to determine that the correct container 314 has been selectedand requires manual fulfillment or manual inspection.

The label module 704 may operate the labeler 336, 418 and provideidentifying data for printing by the labeler 336, 418. Identifying datafor printing may include prescription drug information, patientidentification, order identification, dosage information, or the like.

The robot module 706 may operate the robot 332, 414 to selectively pickthe container 314 from the pallet 312 or the delivery conveyor 420. Therobot module 706 may communicate with the order processing device 102,the scan module 702, and/or the label module 704, for example, tocoordinate scanning and labeling of the container 314. The robot module706 may communicate with the order processing device 102 to coordinatedistribution to the manual section 306.

Once the container 314 is scanned, identifying information may becompared against identifying prescription order data obtained from theorder processing device 102, for example. If a matching prescriptionorder exists, the robot module 706 may operate the robot 332, 414 todistribute the container 314. If not a match, the robot module 706 mayreject the container 314 and operate the robot 332, 414 to place thecontainer 314 aside or distribute to the manual handling area 342, 424.

The conveyor module 708 may operate the distribution conveyor 338, 420and the return conveyor 340, 422. The conveyor module 708 maycommunicate with the robot module 706 to coordinate placement andremoval of the container 314 from the conveyor 338, 340, 420, 422.

FIG. 8 illustrates a method 800 for manual handling, according to anexample embodiment. The method 800 may be performed by the manualfulfillment device 114, by the review device 116 and/or the processingdevice 102, or may be otherwise performed.

At block 802, the container 314 in the pallet 312 is held in the holdingsection 302. The pallet 312 may be identified via the reader 320 asincluding a container 314 to be manually handled. The reader 320 may beused to identify the pallet 312 as having the container 314 requiringmanual handling. The order processing device 102 may signal the holdingsection 302 to hold the pallet 312. The transfer actuator 322 maytransfer the pallet 312 from the feed conveyor 316 and place it on thefirst holding conveyer 324 of the holding section 302. The pallet 312continues to be held while the container 314 is manually handled. In anexample embodiment, a pallet's RFID tag (or other identificationstructure) is read each time it enters or approaches the distributionsection 304. If the pallet 312 is identified as being associated withthe container 314 that is returned from the manual section 306, thepallet 314 stops at the distribution section 304 via stopping of thesecond holding conveyor 326 or stops (not shown), for example. Themanually-filled container 314 is placed back into the pallet 312 via therobot 332. At the pallet's 312 subsequent entry transfer area 318, itsRFID tag may be read by the reader 320. In some embodiments, locationsof the pallets 312 within the holding section 302 are indexed tofacilitate prompt identification for return of the manually filledcontainer 314 to its original pallet 312. If the pallet 312 isidentified as having all manually-filled containers 314 returned, thelift transfer unit 318 may remove the pallet 312 from the first holdingconveyor 324 and return it to the feed conveyor 316. If allmanually-filled containers 314 are not returned, the pallet 312 withmissing containers 314 may circulate within the holding section 302. Thepallet 312 circulates via the first and second holding conveyors 324,326 and the first and second transfer units 328, 330.

At block 804, the container 314 is picked from the holding section 302by the robot 332. The robot module 706 may communicate with theidentification module 604 to coordinate the picking of the container 314requiring manual handling.

At block 806, a prescription order with multiple order components isaccessed to provide identifying data for the container 314. Theidentifying data identifies an attribute of the order component. Theorder component may be the container 314 requiring manual handling, forexample.

At block 808, the container 314 is labeled with a label having theidentifying data thereon. The container 314 may be positioned andorientated at the labeler 336 by the robot 332 for labeling. In someembodiments, the container 314 may already be labeled in such a case,the robot 332 moves the container 314 to the scanner 334.

At block 810, the label of the container 314 is scanned by the scanner334. The container 314 may be positioned and orientated at the scanner334 by the robot 332 for scanning.

At block 812, the container 314 is distributed to the manual section306. The robot 332 may distribute the container 314 to the distributingconveyor 338, which may deliver the container 314 to the handling area342.

At block 814, the container 314 is manually handled according to theidentifying data. Information about the container, such as theidentifying data, may be provided to an operator, e.g., pharmacistand/or pharmacy technician, at the manual section 306. For example,contents of the container 314 may be checked against the identifyingdata on the label. In other examples, the container 314 may be filledwith a prescription drug in accordance with the identifying data on thelabel of the container 314.

At block 816, the container 314 is returned. Returning the container mayinclude returning via the return conveyor 340 to the distributionsection 304 and/or the holding section 302. For example, the container314 is placed on the return conveyor 340 that travels away from themanual section 306 to the distribution section 304, which acts as areloading station for replacement of the container 314 into the pallet312. The distribution section 303 may be a reloading station and anunloading station, for example. In other embodiments, separate reloadingand unloading stations may be used. An unloading station or a reloadingstation may be any one or more points, positions, and/or stations thatremoves the container 314 from the pallet 312 and/or returns thecontainer 314 to the pallet 312.

The manually-filled container 314 is released to the distributionsection 304 and reunited with its originally assigned pallet 312. Forexample, upon or after leaving the manual section 306, a container'slabel may be read by the scanner 334, for example, and the scannedinformation may be used to associate the container 314 with its originalpallet 312.

A pallet 312 may continue to be held in the holding section 302 untilall manually-filled containers 314 have been returned to the pallet 312.

FIG. 9 illustrates a method 900 for manual handling, according to anexample embodiment. The method 900 may be performed by the manualfulfillment device 114, by the review device 116 and/or by the orderprocessing device 102, or may be otherwise performed.

At block 902, a prescription order having multiple order components,e.g. containers 314, is delivered to the distribution section 402. Theprescription order may be delivered by the delivery conveyor 420. Atblock 904, one of the order components from the prescription order isselected. The order component may be selected by the robot 414 from thedelivery conveyor 420. At block 906, the order component is scanned bythe scanner 416. The robot 414 may orientate the order component at thescanner 416. In one embodiment, the order component is labeled by thelabeler 418 before scanning.

At block 908, a determination of whether the order component should bemanually handled or held at the holding section 402 is made. The scanner416 may be used to determine the proper distribution of the ordercomponent.

If the order component requires manual handling, the robot 414 maydistribute the order component to the delivery conveyor 420, which maydistribute the order component to the manual section 406, at block 910.Order components not requiring manual handling may be positioned in thestationary pallet 412 of the holding section 402 by the robot 414.

At block 912, the order component may be manually handled. For example,the order component may be checked for accuracy or may be filled with aprescription drug at the manual section 406. The manual handling mayinclude sending a confirmation code from a device operated by the person(e.g., a pharmacist, pharmacy technician, chemist (e.g., in the UK), orother licensed/trained person to manually handle the order component) toother device and/or modules that interact with the prescription drugfulfillment.

At block 914, the order component is returned from the manual section406 to the distribution section 404. The order component may be returnedvia the return conveyor 422. The manually handled order component iscombined with its companion order components at block 916. The combiningmay include the robot 332, 414 picking the companion order componentsfrom the stationary pallet 412 and distributing onto the return conveyor422 with the manually handled order component such that the prescriptionorder is on the return conveyor 422. The manually handled ordercomponent may be scanned or otherwise identified to signal the robot 414to pick the companion order components from the stationary pallet 412and place on the return conveyor 422. In some embodiments, the robot332, 414 returns the container 314 to the pallet 312 if the confirmationsignal is received from the device associated with the manualfulfillment. The robot 332, 414 may set the container 314 at a differentlocation if the confirmation signal is not received.

FIG. 10 shows a block diagram of a machine in the example form of acomputer system 1000 within which a set of instructions may be executedcausing the machine to perform any one or more of the methods,processes, operations, or methodologies discussed herein. The orderprocessing device 102, the network manager device 106, the manualfulfillment device 114 and/or the review device 116 may include thefunctionality of the one or more computer systems 1000.

In an example embodiment, the machine operates as a standalone device ormay be connected (e.g., networked) to other machines. In a networkeddeployment, the machine may operate in the capacity of a server or aclient machine in server-client network environment, or as a peermachine in a peer-to-peer (or distributed) network environment. Themachine may be a server computer, a client computer, a personal computer(PC), a tablet PC, a gaming device, a set-top box (STB), a PersonalDigital Assistant (PDA), a cellular telephone, a web appliance, anetwork router, switch or bridge, or any machine capable of executing aset of instructions (sequential or otherwise) that specify actions to betaken by that machine. Further, while only a single machine isillustrated, the term “machine” shall also be taken to include anycollection of machines that individually or jointly execute a set (ormultiple sets) of instructions to perform any one or more of themethodologies discussed herein.

The example computer system 1000 includes a processor 1002 (e.g., acentral processing unit (CPU) a graphics processing unit (GPU) or both),a main memory 1004 and a static memory 1006, which communicate with eachother via a bus 1008. The computer system 1000 further includes a videodisplay unit 1010 (e.g., a liquid crystal display (LCD) or a cathode raytube (CRT)). The computer system 1000 also includes an alphanumericinput device 1012 (e.g., a keyboard), a cursor control device 1014(e.g., a mouse), a drive unit 1016, a signal generation device 1018(e.g., a speaker) and a network interface device 1020.

The drive unit 1016 includes a computer-readable medium 1022 on which isstored one or more sets of instructions (e.g., software 1024) embodyingany one or more of the methodologies or functions described herein. Thesoftware 1024 may also reside, completely or at least partially, withinthe main memory 1004 and/or within the processor 1002 during executionthereof by the computer system 1000, the main memory 1004 and theprocessor 1002 also constituting computer-readable media.

The software 1024 may further be transmitted or received over a network1026 via the network interface device 1020.

While the computer-readable medium 1022 is shown in an exampleembodiment to be a single medium, the term “computer-readable medium”should be taken to include a single medium or multiple media (e.g., acentralized or distributed database, and/or associated caches andservers) that store the one or more sets of instructions. The term“computer-readable medium” shall also be taken to include any mediumthat is capable of storing or encoding a set of instructions forexecution by the machine and that cause the machine to perform any oneor more of the methodologies of the present invention. The term“computer-readable medium” shall accordingly be taken to include, butnot be limited to, solid-state memories, and optical media, and magneticmedia. In some embodiments, the computer-readable medium is anon-transitory computer-readable medium.

The term “based on” or using, as used herein, reflects an open-endedterm that can reflect others elements beyond those explicitly recited.

Certain systems, apparatus, applications or processes are describedherein as including a number of modules. A module may be a unit ofdistinct functionality that may be presented in software, hardware, orcombinations thereof. When the functionality of a module is performed inany part through software, the module includes a computer-readablemedium. The modules may be regarded as being communicatively coupled.

The inventive subject matter may be represented in a variety ofdifferent embodiments of which there are many possible permutations.

In an example embodiment, a system is provided with a holding section, adistribution section and a manual section. The holding section isadapted to hold the container during manual handling. The distributionsection is adjacent the holding section and has a robot adapted toselect and pick containers from the holding section. The robot isdisposed to distribute the container. The manual section is disposedadjacent the conveyor. The manual section is adapted for inspection orfilling of the container.

In an example embodiment, a prescription order having a plurality oforder components is held. At least one of the order components is acontainer for prescription drugs. The container is selected from theprescription order. The prescription order is accessed to provideidentifying data for the container. The identifying data identifies anattribute of the prescription order. The container is labeled with alabel having the identifying data. The label of the container isscanned. The container is distributed to a manual handling area.

In an example embodiment, a prescription order having a plurality oforder components is delivered. At least one of the order components is acontainer for prescription drugs. One of the order components isselected from the prescription order. The selected order component isscanned. Whether the selected order component should be inspected orfilled manually is determined. The selected order component isdistributed to a holding section or a manual handling area. The selectedorder component is returned to a return conveyor. The manually handledorder component is combined with companion order components that werenot manually handled to group the prescription order.

The present disclosure makes reference to a robot and words of similarimport. A robot can be a machine capable of carrying out a complexseries of actions automatically. These complex series of actions mayinclude picking up, orientating, positioning and/or releasing acontainer or other structure. The robot may be dedicated to a singleseries of movements or may be able to execute multiple series ofmovements. A robot may include a processor that received instructionsand then executes instructions to control its movement. In anotherexample, a robot may resemble a human being and replicate certain humanmovements and functions, e.g., a robot may move location, have anarticulated arm, have grasping structures that replicate like fingersand do not damage containers, and the like.

Thus, methods and systems for manual handling have been described.Although embodiments of the present invention have been described withreference to specific example embodiments, it will be evident thatvarious modifications and changes may be made to these embodimentswithout departing from the broader spirit and scope of the embodimentsof the invention. Accordingly, the specification and drawings are to beregarded in an illustrative rather than a restrictive sense.

The methods described herein do not have to be executed in the orderdescribed, or in any particular order. Moreover, various activitiesdescribed with respect to the methods identified herein can be executedin serial or parallel fashion. Although “End” blocks are shown in theflowcharts, the methods may be performed continuously.

The Abstract of the Disclosure is provided to comply with 37 C.F.R.§1.72(b), requiring an abstract that will allow the reader to quicklyascertain the nature of the technical disclosure. It is submitted withthe understanding that it will not be used to interpret or limit thescope or meaning of the claims. In addition, in the foregoing DetailedDescription, it can be seen that various features are grouped togetherin a single embodiment for the purpose of streamlining the disclosure.This method of disclosure is not to be interpreted as reflecting anintention that the claimed embodiments require more features than areexpressly recited in each claim. Rather, as the following claimsreflect, inventive subject matter may lie in less than all features of asingle disclosed embodiment. Thus, the following claims are herebyincorporated into the Detailed Description, with each claim standing onits own as a separate embodiment.

1. A method comprising: scanning, by a scanner, a label of a containerfor a quantity of a prescription drug to obtain scanned data;determining, by a processor, whether the container is to be distributedto a manual handling section based on the scanned data; in response tothe container being determined to be distributed to the manual handlingsection, distributing, by a robot, the container from a distributionsection to the manual handling section for manual handling anddistributing companion order components of the prescription drug from aplurality of order components to a holding section when the container isbeing manually handled; routing, by the robot, the container that hasbeen manually handled from the manual handling section to the holdingsection via a delivery conveyor; combining, by the robot, the containercontaining the quantity of the prescription drug with the companionorder components in the holding section to group a prescription order;and returning, by the robot, the prescription order to the distributionsection via a return conveyor.
 2. The method of claim 1, wherein themanual handling section, the distribution section, and the holdingsection are deployed within a high volume pharmacy system for deliveringthe prescription order including the plurality of order components, andwherein at least one of the plurality of order components being thecontainer for the quantity of a prescription drug.
 3. The method ofclaim 1, further comprising transmitting a confirmation code based on anoperation that is completed in the manual handling section.
 4. Themethod of claim 1, wherein combining the container with the companionorder components in the holding section to group the prescription ordercomprises: identifying, in the holding section, a stationary palletamong a plurality of pallets that is associated with the container togroup the prescription order.
 5. The method of claim 4, furthercomprising: picking, by the robot, the container from the deliveryconveyor; and placing the container on the stationary pallet.
 6. Themethod of claim 4, further comprising: respectively assigning a positionon the stationary pallet to the plurality of order components.
 7. Themethod of claim 6, further comprising: indexing the position on thestationary pallet to track a location of the container to therebyfacilitate returning the container to the stationary pallet after beingmanually handled.
 8. The method of claim 6, further comprising:circulating, on a circulating conveyor, the stationary pallet within theholding section and awaiting the container being returned to thestationary pallet from the manual handling section.
 9. The method ofclaim 1, wherein scanning the label of the container further comprises:capturing an image of the label of the container by an image sensor. 10.The method of claim 9, further comprising capturing the image of thelabel of the container by spinning the container for the image sensor toobtain scanned data.
 11. A system comprising: a scanner configured forscanning a label of a container for a quantity of a prescription drug toobtain scanned data; a processor configured for determining whether thecontainer is to be distributed to a manual handling section based on thescanned data; and a robot disposed in a distribution section andconfigured for, in response to the container being determined to bedistributed to the manual handling section, distributing the containerfrom the distribution section to the manual handling section for manualhandling and distributing companion order components of the prescriptiondrug from a plurality of order components to a holding section when thecontainer is being manually handled; routing the container that has beenmanually handled from the manual handling section to the holding sectionvia a delivery conveyor; combining the container containing the quantityof the prescription drug with the companion order components in theholding section to group a prescription order; and returning theprescription order to the distribution section via a return conveyor.12. The system of claim 11, wherein the manual handling section, thedistribution section, and the holding section are deployed within a highvolume pharmacy system for delivering the prescription order includingthe plurality of order components, and wherein at least one of theplurality of order components being the container for the quantity of aprescription drug.
 13. The system of claim 11, further comprising adevice disposed in the manual handling section and configured fortransmitting a confirmation code based on an operation that is completedin the manual handling section.
 14. The system of claim 11, wherein therobot comprises a reader configured for identifying, in the holdingsection, a stationary pallet among a plurality of pallets that isassociated with the container to group the prescription order.
 15. Thesystem of claim 14, wherein the robot is further configured for: pickingthe container from the delivery conveyor; and placing the container onthe stationary pallet.
 16. The system of claim 15, wherein each of theplurality of order components is assigned a position on the stationarypallet.
 17. The system of claim 16, wherein the position on thestationary pallet is indexed to track a location of the container tothereby facilitate returning the container to the stationary palletafter being manually handled.
 18. The system of claim 16, the stationarypallet is circulated on a circulating conveyor within the holdingsection awaiting the container being returned to the stationary palletfrom the manual handling section.
 19. The system of claim 11, whereinthe scanner is an image sensor configured for capturing an image of thelabel of the container.
 20. The system of claim 19, wherein the robot isconfigured for spinning the container while the image sensor iscapturing the image of the label of the container to obtain the scanneddata.